I was installing my invidia O2 housing (among other goodies) tonight and I can't get the O2 sensor out of the stock O2 housing. Now, the easy solution is to buy a new O2 sensor. The predicament that I am in is that I have an appointment to get tuned this coming Saturday (Nov 29th). Normally, I would sack up, go to autozone/kragen and spend the money to buy a new one. Problem with this is that they are ~$400 and I can only imagine what they are from a dealership.

Is there any way to get this sensor out? I have applied what should be an illegal amount of pb blaster to the thing. Impact wrench hasn't done the trick; neither has putting the O2 housing in a vice and giving it all I've got. If nothing else, I am going to to take it to an auto shop on Friday and see if they have any ideas on how to get it out.

Any help is appreciated.

 

big *** vise grip + torch

 

put the housing in a vice , put a wrench on it, try and get a torch on it and after its hot give the wrench a couple hits with a hammer to try and break it loose.

Also try a crowsfoot wrench/o2 sensor socket and a big breaker bar

 

If it's that hard to get your 02 sensor out, then I will bet that your threads are damaged. I've removed a few 02 sensors that were original from the factory and seized onto the exhaust. Upon removing them, found the threads of the 02 sensors totally broken off and formed part of the threads of the exhaust/ manifold. These were original factory 02 sensors, never replaced, so they weren't cross-threaded from replacement. The damaged 02 sensors cannot be re-used (no more threads), but the the exhaust side threads can be repaired with a spark plug thread chaser and some patience.

 

I got a Bosch Universal o2 sensor because mine wouldnt come out of the o2 housing either. Cost me $50.

The o2 sensor sockets are a joke. Just spend $50 for a universal, it will work just as well.

 

I'd buy a new one...... Just in case. What if you wanna put it back to stock and it breaks when you're taking it out?
just my 2 cents.

 

that's the plan for tomorrow. did all that except the torch part. i'm praying that works.

Can you get those at autozone/kragen? I have heard good and bad things about universals... but that said, if I have to buy a new one - it will be a universal. I'm not paying 400 bucks for one of these things

I definitely have that fear. Even though I'm taking off the stock 02 housing, it would be nice to have it in working order in the event I want to go back to stock.

It may come to this, but buying a new one means (I think) waiting for one to be shipped to me - a decently priced universal one, that is. I really don't want to have to delay my tuning appointment

 

I believe autozone should have them. Check around...I've had a universal in my car for 2 weeks now, no problems thus far.

 

I had this happen to me on a car i was working on at work. I used brake fluid(when it was hot) to try and cool it down. But if yours is cooled down. Try some brake clean by the end where it meets 02 hosuing or some lubricant. if that doesn't work try the good old torch idea! just be careful

 

I have been in this predicatment also. You will not be able to save the sensor that is in there now. I would try to get a deep impact socket without the notch cut in it for the wire. You'll have to cut the wire off. If that doesn't work heat it up really good until glowing red hot and hit it with the impact wrench again. If that doesn't work cut the top of the o2 sensor off with a sawsal or hack saw. Then with a dremel and chisel cut the remainder of the sensor out of the threaded hole. I once had to take it all the way to the chisel and hammer. Don't even waste time with crows feet sockets or penetrating oil. The oils will not penetrate at all because of the crush washer. Remeber anti sieze when putting the new one in and don't over tighten it.

 

heat it up real hot

 

use a monkey wrench and heat it up

 

I had to use a pipe wrench, heat, and a pipe for leverage.

 

Did this 3 days ago. I couldn't get it out, so I took it to a machine shop where they torched it for a couple minutes, came right out. It's amazing how much the heat expands it and loosens everything up.